Continuous Animal Feed Metering with Master Component Control
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Solution Overview
Problem
Existing animal feed production methods require high energy consumption, result in large space requirements, and are costly due to the batch processing of feed components, leading to inefficiencies and high acquisition costs, especially when producing large quantities.
Innovation Solution
A method and device for continuous metering and processing of feed components, where the metering and processing performance are controlled based on a master component, allowing for optimized operation of system components and reducing the need for high-powered machinery, with the option to change the master component dynamically to maintain efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch processing is used with high-powered mixers and mills, then large quantities of animal feed can be produced, but energy consumption increases and current peaks occur during startup
Solution Approach 1:
Feed components are pre-processed (crushing, grinding) before mixing in smaller, continuously operating units. This preliminary action allows the use of smaller, energy-efficient equipment rather than requiring large high-powered mixers and mills that consume excessive energy and generate current peaks during startup.
Solution Approach 2:
The system operates continuously with multiple smaller processing units working in parallel rather than using batch processing with single large units. This continuous operation eliminates startup current peaks and maintains steady-state energy consumption, significantly reducing overall energy usage while maintaining high productivity.
2Productivity
If batch processing with large mixers is used, then large quantities of feed can be produced, but space requirements increase
Solution Approach 1:
The production system is segmented into multiple smaller processing units (multiple mills, multiple mixers) operating in parallel rather than using a single large batch processor. This segmentation reduces the space footprint of individual units while maintaining or increasing overall productivity through concurrent operation.
Solution Approach 2:
The system transitions from vertical stacking of large equipment to a more distributed horizontal arrangement of smaller units, or utilizes three-dimensional space more efficiently with compact modular designs. This dimensional optimization allows high productivity within reduced space constraints.
3Productivity
If high-powered processing equipment is used, then large quantities of feed can be produced quickly, but acquisition costs increase
Solution Approach 1:
The system uses multiple smaller processing units instead of one or two large expensive units. This segmentation reduces capital expenditure because smaller units are less costly to manufacture and install, while the combined capacity of multiple units achieves the required productivity level.
Solution Approach 2:
The system employs variable speed drives and controllable processing rates on each unit, allowing flexible operation and optimization. This dynamic control enables the system to match production demand precisely, avoiding the need for oversized equipment that would be expensive to acquire and operate at partial capacity.
4Manufacturing precision
If metering output is changed in a controlled manner, then precise recipe adherence is achieved, but system complexity increases
Solution Approach 1:
The system incorporates feedback control where the actual metering output is monitored and compared to the target recipe proportions, with automatic adjustments made to maintain precision. This feedback mechanism achieves accurate recipe adherence through relatively simple proportional control rather than complex multi-variable optimization.
Solution Approach 2:
The system controls metering by adjusting key parameters such as screw speed, gate opening, or feed rate of each component in proportion to the recipe requirements. These parameter changes are implemented through simple proportional control mechanisms that maintain precision without requiring complex control systems.
Data Source
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AI summary
The invention relates to a method and a system (device) for producing animal feed from feed components (K1-K8) consisting of several dry substances and at least one liquid substance with weight proportions according to a predetermined recipe, wherein the individual feed components (K1-K8) are metered from storage containers (3-9, 41-43) via metering devices (11-20, 61) whose metering capacity can be controlled and varied, are measured by weight by means of weighing devices (31-37, 62) and are fed to a mixing device (50) by means of a conveying device (40), wherein at least one feed component is ground from dry feed before mixing, e.g. by means of a mill (21, 22).In order to enable a high hourly output of animal feed to be produced with low energy consumption, reduced acquisition costs and small space requirements, according to the invention the feed components (K1-K8) are continuously taken from all storage containers (3-9, 41-43) and the dosing capacity of all dosing devices (11-20, 61) is controlled in a power-regulated manner depending on a lead component, wherein the lead component is always the feed component for which the associated dosing or processing device has the lowest power reserves compared to operation under full load.